Heat Controller BG-103A User manual

Brand
Heat Controller
Model
BG-103A
Type
User manual

This manual is also suitable for

Service Manual
CAUTION
-Before servicing the unit, read the "safety precautions" in this manual.
-Only for authorized service personnel.
Through-The-Wall
Air Conditioning
HEAT CONTROLLER, INC.
Model: BG-103A
—2—
1. PREFACE
1.1 SAFETY PRECAUTIONS ...............................2
1.2 INSULATION RESISTANCE TEST.................2
1.3 SPECIFICATIONS ..........................................3
1.4 FEATURES.....................................................4
1.5 CONTROL LOCATIONS.................................4
2.
DISASSEMBLY INSTRUCTIONS
2.1 MECHANICAL PARTS....................................5
2.1.1 FRONT GRILLE.....................................5
2.1.2 CABINET................................................5
2.1.3 CONTROL BOX.....................................5
2.2 AIR HANDLING PARTS..................................6
2.2.1 ORIFICE AND TURBO FAN
................. 6
2.2.2 FAN........................................................6
2.2.3 SHROUD................................................7
2.3 ELECTRICAL PARTS.....................................7
2.3.1 MOTOR..................................................7
2.3.2 COMPRESSOR .....................................7
2.3.3 CAPACITOR ..........................................7
2.3.4 POWER CORD......................................8
2.3.5 THERMISTOR .......................................8
2.4 REFRIGERATION CYCLE.................................9
2.4.1 CONDENSER ......................................9
2.4.2 EVAPORATOR ....................................9
2.4.3 CAPILLARY TUBE...............................9
3.
INSTALLATION
3.1 INSTALLATION REQUIREMENTS...............12
3.2 INSTALLATION.............................................13
3.3 PROCEDURE A............................................14
3.4 PROCEDURE B............................................15
3.5 PROCEDURE C............................................17
4.
TROUBLESHOOTING GUIDE
4.1 OUTSIDE DIMENSIONS...............................19
4.2 PIPING SYSTEM ..........................................19
4.3 TROUBLESHOOTING GUIDE......................20
5. SCHEMATIC DIAGRAM
5.1 CIRCUIT DIAGRAM......................................25
6. EXPLODED VIEW..................................26
7. REPLACEMENT PARTS LIST .......27
1. PREFACE
This SERVICE MANUAL provides various service information, including the mechanical and electrical
parts etc. This room air conditioner was manufactured and assembled under a strict quality control system.
The refrigerant is charged at the factory. Be sure to read the safety precautions prior to servicing the unit.
1.1 SAFETY PRECAUTIONS
1. When servicing the unit, turn off the air conditioner
and unplug the power cord.
2. Observe the original lead dress.
If a short circuit is found, replace all parts which
have been overheated or damaged by the short
circuit.
3. After servicing the unit, make an insulation
resistance test to protect the customer from being
exposed to shock hazards.
1.2
INSULATION RESISTANCE TEST
1. Unplug the power cord and connect a jumper
between 2 pins (black and white).
2. The grounding conductor (green or green & yellow)
is to be open.
3. Measure the resistance value with an ohm meter
between the jumpered lead and each exposed
metallic part on the equipment.
4. The value should be over 1M .
CONTENTS
—3—
1.3 SPECIFICATIONS
1.3.1 FOR BG-103A
POWER SUPPLY
COOLING CAPACITY (Btu/h)
INPUT (W)
RUNNING CURRENT (A)
E.E.R (Btu/W.h)
OPERATING INDOOR(°C)
TEMPERATURE OUTDOOR(°C)
REFRIGERANT (R-22) CHARGE (g)
EVAPORATOR
CONDENSER
FAN, INDOOR
FAN, OUTDOOR
FAN SPEED (FAN/COOLING/HEATING)
FAN MOTOR
OPERATION CONTROL
ROOM TEMP. CONTROL
AIR DIRECTION CONTROL
CONSTRUCTION
PROTECTOR COMPRESSOR
FAN MOTOR
POWER CORD
DRAIN SYSTEM
NET WEIGHT (lbs/kg)
DIMENSION (inch)
(W x H x D) (mm)
SLEEVE DIMENSION (inch)
(W x H x D) (mm)
SLEEVE DEPTH (inch)
WITH FRONT GRILLE (mm)
BG-103A REMARK
Model
Items
1Ø, 230/208V, 60Hz
10,500 / 10,000
1,230 / 1,170
5.7 / 6.0
8.5 / 8.5
26.7(DB) 19.4(WB)
35(DB) 23.9(WB)
475g(16.8OZ)
3ROW 12STACKS
2ROW 17STACKS, L-BENDING TYPE
LOUVERED-FIN TYPE
TURBO FAN
PROPELLER TYPE FAN WITH SLINGER-RING
3/3
4POLES
ELECTRIC
THERMISTOR
VERTICAL LOUVER(RIGHT & LEFT)
HORIZONTAL(UP & DOWN)
TOP-DOWN
EXTERNAL OVERLOAD PROTECTOR
INTERNAL THERMAL PROTECTOR
1.4m (3WIRES WITH GROUNDING)
ATTACHMENT PLUG(CORD-CONNECTED TYPE, LCDI)
SPLASHED BY FAN SLINGER
80/36
24 x 14
13
/32 x 20
3
/32
610 x 366 x 499
25
7
/8 x 15
17
/32 x 16
23
/32
20
1
/2
656 x 394 x 425
521
1.4 FEATURES
• Designed for cooling only.
• Powerful and quiet cooling.
• Top-down chassis for the simple installation and service.
1.5 CONTROL LOCATIONS
1.5.1 COOLING ONLY MODEL
• OPERATION
• Side air-intake, side cooled-air discharge.
• Built in adjustable THERMISTOR and THERMOSTAT.
• Washable one-touch filter.
• Compact size.
• VENTILATION
Push the lever to the "CLOSE" position to cool, heat or recirculate room air only.
Pull the lever to the "OPEN" position to exhaust smoke or stale air from the room.
This feature is best used in conjunction with the FAN ONLY position.
—4—
PULL OPEN / PUSH CLOSE
MODE TIMER POWER
FAN
SPEED
Fan
Energy
Saver
Cool
Timer
TEMP
'
F
F1 LOW
F2 MED
F3 HIGH
REMOTE CONTROL SIGNAL RECEIVER
POWER
MODE
-
Push this button to shift mode of operation from COOL → ENERGY SAVER → FAN.
- COOL:
• Fan runs continually for normal cooling operation.
- ENERGY SAVER:
• The fan stops when the compressor stops cooling. Approximately every 3 minutes the fan will turn on and the unit will check the room air
temperature to determine if cooling is needed.
- FAN:
• Fan-only operation.
TIMER
- SHUT-OFF TIME
• You will usually use shut-off time while you sleep.
• If unit is running, use Timer to set number of hours until shut-off.
• For your sleeping comfort, once Time is set, the Temperature setting will raise 2°F after 30 min., and once again after another 30 min.
• Push Timer button to advance setting from 1Hour → 2Hours → ... → 12Hours maximum.
- START TIME
• If unit is off, use Timer to set number of hours before unit starts.
• Push Timer button to advance setting from 1Hour → 2Hours → ... → 12Hours maximum.
TEMPERATURE SETTING
• Use this button to automatically control the temperature of the room.
The temperature can be set within a range of 60°F to 86°F by increments of
1°F.
• The setting appears in the display.
• To turn the air conditioner ON, push this button.
To turn the air conditioner OFF, push the button again.
• This button takes priority over any other button.
• When you first turn it on, the unit is in cool mode, High fan speed,
Temperature setting at 72°F.
FAN SPEED
• Every time you push this button, it advances the setting as follows:
{High → Low → Med → High}
When the air conditioner has been operating in the
cooling and is turned off or set to the fan only position,
wait at least 3 minutes before resetting to the cooling
operation again.
CAUTION
—5—
2.1 MECHANICAL PARTS
2.1.1 FRONT GRILLE
1. Open the inlet grille downward.
2. Remove the screw which fastens the front grille.
3. Pull the front grille from the right side.
4. Remove the front grille. (See Fig. 1)
5. Re-install the component by referring to the
removal procedure.
2.1.2 CABINET
1. After disassembling the FRONT GRILLE, remove
the 6 screws which fasten the cabinet at the both
sides and the top. (See Fig. 2)
Keep these for later use.
2.1.3 CONTROL BOX
1. Remove the front grille. (Refer to section 2.1.1)
2. Remove the screw which fasten the control
box. (See Fig. 3)
3. Pull the control box from the barrier.(See Fig.3)
4. Discharge the capacitor by placing a 20,000 ohm
resistor across the capacitor terminals.
5. Disconnect two wire housings in the control box.
6. Pull the control box forward completely.
7. Re-install the components by referring to the
removal procedure. (See Fig. 3)
(Refer to the circuit diagram found on pages 25 in
this manual and on the control box.)
2. DISASSEMBLY INSTRUCTIONS
— Prior to disassembling the unit, make sure that the POWER is off and the power cord is unplugged from the
wall receptacle.
M
O
D
E
T
I
M
E
R
P
O
W
E
R
FAN
SPEED
F
a
n
E
n
e
r
g
y
S
a
v
e
r
C
o
o
l
T
i
m
e
r
TEMP
'
F
F
1
L
O
W
F2
ME
D
F
3
H
IG
H
Figure 1
Figure 2
MODE
TIMER
POWER
F
A
N
S
P
E
E
D
F
a
n
Energy
Saver
C
o
o
l
T
im
e
r
T
E
M
P
'
F
F
1
L
O
W
F
2
M
E
D
F
3
H
I
G
H
M
O
D
E
T
I
M
E
R
P
O
W
E
R
F
A
N
S
PEE
D
Fa
n
E
n
e
r
g
y
S
a
v
e
r
C
o
ol
Tim
er
T
E
MP
'
F
F
1
L
O
W
F
2
M
E
D
F
3
H
I
G
H
MODE TIMER POWER
FAN
SPEED
Fan
Energy
Saver
Cool
Timer
TEMP
'
F
F1 LOW
F2 MED
F3 HIGH
Figure 3
Figure 7
—6—
2.2 AIR HANDLING PARTS
2.2.1 ORIFICE, AND TURBO FAN
1. Remove the front grille. (Refer to section 2.1.1)
2. Remove the cabinet. (Refer to section 2.1.2)
3. Remove the 2 screws which fasten the
evaporator at the left side and the right side.
(See Fig. 4)
4. Move the evaporator sideward carefully.
5. Remove the orifice. (See Fig. 5)
8. Using handheld pliers, remove the clamp which
secures the turbo fan. (See Fig. 6)
9. Remove the turbo fan with pliers or your hand,
without touching blades. (See Fig. 7)
10. Re-install the components by referring to the
removal procedures, above.
2.2.2 FAN
1. Remove the cabinet. (Refer to section 2.1.2)
2. Remove the brace.
(Refer to section 2.2.1)
3. Remove the 7 screws which fasten the condenser.
4. Move the condenser sideways carefully.
5. Using handheld pliers, remove the clamp which
secures the fan.
6. Remove the fan. (See Fig. 8)
7. Re-install the components by referring to the
removal procedures, above.
M
O
D
E
T
I
M
E
R
P
O
W
E
R
F
A
N
S
P
E
E
D
F
a
n
E
n
e
r
g
y
S
a
v
e
r
C
o
o
l
T
i
m
e
r
T
EM
P
'
F
F
1
L
O
W
F
2
M
E
D
F
3
H
I
G
H
M
O
D
E
T
I
M
E
R
P
O
W
E
R
FA
N
S
P
E
E
D
F
a
n
E
n
e
r
g
y
S
a
v
e
r
C
o
o
l
T
i
m
e
r
T
EMP
'
F
F1
L
O
W
F
2
M
E
D
F
3
H
I
G
H
Figure 4
Figure 5
Figure 6
M
O
D
E
T
I
M
E
R
P
O
W
E
R
F
A
N
S
P
E
E
D
F
a
n
E
n
e
r
g
y
S
a
v
e
r
C
o
o
l
T
i
m
e
r
TEM
P
'
F
F
1
L
O
W
F
2
M
E
D
F
3
H
I
G
H
Figure 8
—7—
2.2.3 SHROUD
1. Remove the fan. (Refer to section 2.2.2)
2. Remove the shroud. (See Fig. 9)
3. Re-install the components by referring to the
removal procedures, above.
2.3 ELECTRICAL PARTS
2.3.1 MOTOR
1. Remove the cabinet. (Refer to section 2.1.2)
2. Remove the clamp cord and disconnect the wire
housing in control box. (Refer to section 2.1.3)
3. Remove the turbo fan. (Refer to section 2.2.2)
4. Remove the fan. (Refer to section 2.2.2)
5. Remove the 4 or 2 screws which fasten the motor.
(See Fig. 10)
6. Remove the motor.
7. Re-install the components by referring to the
removal procedures, above.
2.3.2 COMPRESSOR
1. Remove the cabinet. (Refer to section 2.1.2)
2. Discharge the refrigerant system using a Freon
TM
Recovery System.
If there is no valve to attach the recovery system
to, install one (such as a WATCO A-1) before
venting the Freon
TM
. Leave the valve in place after
servicing the system.
3. Disconnect the 3 leads from the compressor.
4. After purging the unit completely, unbraze the
suction and discharge tubes at the compressor
connections.
5. Remove the 3 nuts and the 3 washers which
fasten the compressor. (See Fig. 11)
6. Remove the compressor.
7. Re-install the components by referring to the
removal procedures, above.
2.3.3 CAPACITOR
1. Remove the control box. (Refer to section 2.1.3)
2. Remove the 1 screw
3. Open the control box
4. Disconnect all the leads on the capacitor terminals.
5. Re-install the components by referring to the
removal procedures, above.
M
O
DE
TIM
ER
P
O
W
E
R
FAN
SPEED
F
a
n
E
n
e
rg
y
S
a
v
e
r
C
o
o
l
T
i
m
e
r
TE
M
P
'
F
F1 LOW
F2 MED
F3 HIGH
Figure 9
Figure 10
Figure 11
Figure 12
—8—
2.3.4 POWER CORD
1. Remove the control box. (Refer to section 2.1.3)
2. Unfold the control box. (Refer to section 2.3.3)
3. Disconnect the grounding screw from the Base
pan.
4. Disconnect 2 receptacles.
5. Remove a screw which fastens the clip cord.
6. Pull the power cord. (See Fig. 13)
7. Re-install the components by referring to the
removal procedure, above.
(Use only one ground-marked hole, , for ground
connection.)
8. If the supply cord of this appliance is damaged, it
must be replaced with the factory-authorized and
specified cord.
2.3.5 THERMISTOR
1. Remove the control box. (Refer to section 2.1.3)
2. Unfold the control box. (Refer to section 2.3.3)
3. Disconnect all the leads of thermistor terminals.
4. Remove the thermistor. (See Fig. 14)
5. Re-install the components by referring to the
removal procedures, above.
MODE
TIMER
POWER
FAN
SPEED
Fan
Energy
Saver
C
ool
Tim
er
TEMP
'
F
F1 LOW
F2 MED
F3 HIGH
Figure 13
Figure 14
—9—
2.4 REFRIGERATION CYCLE
2.4.1 CONDENSER
1. Remove the cabinet. (Refer to section 2.1.2)
2. Remove the brace.
(Refer to section 2.2.1)
3. Remove the 7 screws which fasten the condenser.
4. After discharging the refrigerant completely into a
Freon
TM
Recovery System, unbraze the
interconnecting tube at the condenser
connections.
5. Remove the condenser.
6. Re-install the components by referring to the notes
(See Fig. 15)
2.4.2 EVAPORATOR
1. Remove the cabinet. (Refer to section 2.1.2)
2. Discharge the refrigerant completely – into a
Freon
TM
Recovery System.
3. Remove the 2 screws which fasten the evaporator
at the left side and the right side.
4. Move the evaporator sideward carefully and then
unbraze the interconnecting tube at the evaporator
connectors.
5. Remove the evaporator.
6. Re-install the components by referring to the notes
(See Fig. 16)
2.4.3 CAPILLARY TUBE
1. Remove the cabinet. (Refer to section 2.1.2)
2. After discharging the refrigerant completely – into
a Freon
TM
Recovery System, unbraze the
interconnecting tube at the capillary tube.
3. Remove the capillary tube.
4.
Re-install the components by referring to the notes.
Figure 15
Figure 16
M
O
D
E
T
I
M
E
R
P
O
W
E
R
FAN
SP
EED
F
a
n
E
n
e
r
g
y
S
a
v
e
r
C
o
o
l
T
im
e
r
TEMP
'
F
F
1
L
OW
F
2 ME
D
F3
HIGH
Discharge the refrigerant system using a Freon
TM
Recovery System.
If there is no valve to attach the recovery system,
install one (such as a WATCO A-1) before
venting the Freon
TM
. Leave the valve in place
after servicing the system.
CAUTION
—10—
— Replacement of the refrigeration cycle.
1. When replacing the refrigeration cycle, be sure to
discharge the refrigerant system using a Freon
TM
recovery System.
If there is no valve to attach the recovery system,
install one (such as a WATCO A-1) before venting
the Freon
TM
. Leave the valve in place after
servicing the system.
2. After discharging the unit completely, remove the
desired component, and unbrace the pinch-off
tubes.
3. Solder service valves into the pinch-off tube ports,
leaving the valves open.
4. Solder the pinch-off tubes with Service valves.
5. Evacuate as follows.
1) Connect the vacuum pump, as illustrated Fig.
17A.
2) Start the vacuum pump, slowly open manifold
valves A and B with two full turns
counterclockwise and leave the valves closed.
The vacuum pump is now pulling through valves
A and B up to valve C by means of the manifold
and entire system.
3) Operate the vacuum pump for 20 to 30 minutes,
until 600 microns of vacuum is obtained. Close
valves A and B, and observe vacuum gauge for
a few minutes. A rise in pressure would
indicate a possible leak or moisture remaining in
the system. With valves A and B closed, stop
the vacuum pump.
4) Remove the hose from the vacuum pump and
place it on the charging cylinder. See Fig. 17B.
Open valve C.
Discharge the line at the manifold connection.
5) The system is now ready for final charging.
6. Recharge as follows :
1) Refrigeration cycle systems are charged from the
High-side. If the total charge cannot be put
in the High-side, the balance will be put in the
suction line through the access valve which you
installed as the system was opened.
2)
Connect the charging cylinder as shown in Fig. 17B.
With valve C open, discharge the hose at the
manifold connection.
3) Open valve A and allow the proper charge to
enter the system. Valve B is still closed.
4) If more charge is required, the high-side will not
take it. Close valve A.
5) With the unit running, open valve B and add the
balance of the charge.
a. Do not add the liquid refrigerant to the Low-
side.
b. Watch the Low-side gauge; allow pressure to
rise to 30 lbs.
c. Turn off valve B and allow pressure to drop.
d. Repeat steps B and C until the balance of the
charge is in the system.
6) When satisfied the unit is operating correctly,
use the pinch-off tool with the unit still running
and clamp on to the pinch-off tube. Using a tube
cutter, cut the pinch-off tube about 2 inches from
the pinch-off tool. Use sil-fos solder and solder
pinch-off tube closed. Turn off the unit, allow it to
set for a while, and then test the leakage of the
pinch-off connection.
NOTES
If high vacuum equipment is used, just crack
valves A and B for a few minutes, then open
slowly with the two full turns counterclockwise.
This will keep oil from foaming and being
drawn into the vacuum pump.
CAUTION
—11—
Equipment needed: Vacuum pump, Charging cylinder, Manifold gauge, Brazing equipment. Pinch-off tool
capable of making a vapor-proof seal, Leak detector, Tubing cutter, Hand Tools to remove components, Service
valve.
A
COMPOUND GAUGE
EVAPORATOR
(LOW PRESSURE SIDE)
COMPRESSOR
CAPILLARY TUBE
CONDENSER
(HIGH PRESSURE SIDE)
SEE INSETS
BELOW
MANIFOLD
GAUGE
B
Figure 17A-Pulling Vacuum
Figure 17B-Charging
A
B
EXTERNAL
VACUUM PUMP
A
CHARGING
CYLINDER
LOW
HI
B
C
—12—
3. INSTALLATION
3.1 INSTALLATION REQUIREMENTS
If you use an existing wall sleeve, you should measure its
dimensions.
Install the new air conditioner according to these installation
instructions to achieve the best performance. All wall sleeves
used to mount the new air conditioner must be in good
structural condition and have a compatible rear grille in order
to securely attach the new air conditioner. (FIG. 18A)
With the FRIEDRICH USC sleeve, you can maintain the
best performance of the new air conditioner. (FIG. 18B)
ELECTRICAL SERVICE
Check your available electrical service. The power supply
available must be the same as that shown on the unit
nameplate (found on left side of cabinet).
All models are equipped with a 3-prong service plug to
provide proper service and safe positive grounding. Do not
change plug in any way. Do not use an adapter plug. If your
present wall outlet does not match your plug, call a qualified
electrician to make the necessary corrections. SAVE
CARTON for storage and this OWNER'S MANUAL for future
reference. The carton is the best way to store unit during
winter or when not in use.
INSTALLATION HARDWARE
To avoid risk of personal injury, property damage, or
product damage due to the weight of this device and sharp
edges that may be exposed:
• Air conditioners covered in this manual pose an
excessive weight hazard. Two or more people are
needed to move and install the unit.
To prevent injury or strain, use proper lifting and carrying
techniques when moving unit.
• Carefully inspect location where air conditioner will be
installed. Be sure it will support the weight of the unit
over an extended period of time.
• Handle air conditioner with care. Wear protective gloves
whenever lifting or carrying the unit. AVOID the sharp
metal fins of front and rear coils.
• Make sure air conditioner does not fall during installation.
CAUTION
REQUIRED TOOLS:
• Tight Fitting gloves
• Standard screwdriver
• Phillips screwdriver
• Pliers
• Sharp knife
• 3/8-inch open end
wrench or adjustable
wrench
• 1/4-inch hex socket
and ratchet
• Tape measure
• Electric drill
• 1/4-inch drill bit
14-
13
/
32
"
(366 mm)
24"(610 mm)
18-
15
/
32
"(468 mm)
20-
3
/
32
"
(511 mm)
FIG. 18A
Air Conditioner
15-
17
/32"
(394 mm)
16-
23
/32"
(425 mm)
25-
7
/8"
(656 mm)
aluminum metal grille
FIG. 18B
FRIEDRICH USC Wall Sleeve
ITEM NAME OF PARTS Q'TY
PLASTIC GRILLE 1
VERTICAL INSULATION STRIP 1
AROUND INSULATION STRIPS 2
HORIZONTAL INSULATION STRIP 1
SUPPORT BLOCK 2
BAFFLE 1
TRIM FRAME 2
SHIM 2
PLASTIC NUTS AND WASHER SCREWS
4
1
5
6
7
8
3
2 4
9
2 Size options
2 Size options
—13—
3.2 INSTALLATION
• Pick a location which will allow the conditioned air to blow
into the area you want. Good installation with special
attention to the proper position of the unit will lessen the
chance that service will be needed.
ITEMS IN INSTALLATION HARDWARE
You may not need all parts in the kit. Discard unused parts
HOW TO INSTALL
Before installing the unit, identify the existing wall sleeve
from the list below.
NOTE: All wall sleeves used to mount the new Air
Conditioner must be in sound structural condition and have a
rear grille that securely attaches to sleeve, or rear flange that
serves as a stop for the Air Conditioner.
Remove old air conditioner from existing wall sleeve.
Clean the interior of an existing sleeve.
(Do not disturb seals.)
Wall sleeve must be securely fastened in wall before
installing the air conditioner. Use the nails or screws
through sleeve into wall, if needed. Repaint sleeve if
needed.
Prepare the wall sleeve for installation of the unit. If you
plan to use your existing wall sleeve, and it is not
FRIEDRICH, use procedure B or C below.
Install new unit into wall sleeve.
CAUTION: When installation is completed, replacement unit
MUST have a rearward slope as shown. To achieve 1/4"
slope, remove the backing from the 11-13/16" shim strips and
attach them as shown below in Fig. 19. Place the higher
portion of shim to the front of the rib on base of wall sleeve.
1
2
3
4
5
6
1/4"
Wall Sleeve
FRONT
UNIT
SHIM PLACEMENT UNIT INSTALLATION
1" high
3
/
4
" High
Shim
6" 6"
FIG. 19
Installing the FRIEDRICH USC sleeve ensures
optional performances of the unit.
If you decide to keep the existing wall sleeve, you have
to redirect the louvers at the back of the wall sleeve.
Refer to FIG. 23 on p15. The use of pliers is
recommended. If you DO NOT redirect, you run the risk
of poor performance or premature product failure. This
is not covered under the terms of the FRIEDRICH
warranty.
Procedure Brand
Depth(inches)
A(page 16)
FRIEDRICH USC 16-23/32
White-Westinghouse
Frigidaire Carrier
16, 17-1/2
(52F series)
or 22
General Electric
16-7/8
/Hotpoint
Whirlpool 17-1/8 or 23
Carrier (51S series)
18-5/8
Fedders/Emerson 16-3/4
Friedrich WSC or 19-3/4
Emerson/Fedders 15
B
(pages 17~18)
C
(pages 19)
ITEM (inches) Qty.
Plastic grille 26
3
/
4
x 16
1
/
2
1
Vertical insulation strip 15
9
/
16
x 1
3
/
8
x 1
3
/
8
1
Around Insulation Strips
67
1
/
8
x 1
3
/
8
x
25
/
32
1
59
27
/
32
x 1
3
/
8
x 1
3
/
8
1
Horizontal Insulation Strip 23
7
/32 x 1
3
/
8
x 1
3
/16 1
Support Block 1
3
/
4
x 1
3
/
8
x 4
5
/
16
2
Baffle
14 x
4
1
/
2
x
1
/
8
1
Shim 11
13
/
16
x 1 x
3
/
4
2
Trim Frame 2
Washer Screw 4
Nuts(Plastic) 4
Grille Rear 1
CAUTION
Wall Sleeve Dimensions (inches)
Brand
Width Height Depth
White-Westinghouse
25-1/2 15-1/4
16, 17-1/2
Frigidaire
or 22
Carrier (52F series)
General Electric
26 15-5/8 16-7/8
/Hotpoint
Whirlpool 25-7/8 16-1/2
17-1/8
or 23
Fedders/Emerson
27 16-3/4
16-3/4
Friedrich WSC or 19-3/4
FRIEDRICH USC 25-7/8 15-17/32 16-23/32
Emerson/Fedders 26-3/4 15-3/4 15
Carrier (51S Series) 25-3/4 16-7/8 18-5/8
PROCEDURE
If you are using the new sleeve (optionally
A
suppliedwithyourunit),skiptostep3.
Otherwise, install the plastic grille from the kit.
Cut the plastic grille to 25-1/2" wide and
15-1/4" high. Place the plastic grille to the
inside of the wall sleeve at the rear flange.
Fasten the 4 washer screws to secure the grille
to the wall sleeve. If you need plastic nuts to
mount plastic grille to the inside of the wall
sleeve, there are plastic nuts in the installation
kit. The nuts are installed from the inside of the
sleeve and are pressing into the square holes
of the rear flanges.Fasten the bracket to the
upside of the wall sleeve using the washer
screw. The bracket prevents the unit from
leaving the sleeve.
Remove the backing from the Vertical
Insulation strip 15
9
/
16
x1
3
/
8
x1
3
/
8
and attach that
totheinsiderightofthesleeveasshown
below. Remove the backing from the Around
Insulation strip 67
1
/
8
x1
3
/
8
x
25
/
32
and attach that
to the inside front of the sleeve as shown
below.
FIG.20
Around Insulation
9
1
/
2
"6"
Indoor Outdoor
FIG. 22
or
Bracket Bracket
FIG.21
Fasten the screws and the bracket
1
2
3
4
5
Wall
Trim (2 ea)
FIG.23
• Air conditioners covered in this manual pose an
excessive weight hazard. Two or more people are
needed to move and install the unit.
To prevent injury or strain, use proper lifting and
carrying techniques when moving unit.
• When handling the air conditioner, be careful to avoid
cuts from sharp metal fins on front and rear coils.
• Make sure air conditioner does not fall during
removal.
• If unit does not operate after installation check, to be
sure the circuit interrupter has not been tripped. Refer
to the Troubleshooting guide for reset procedure.
CAUTION
Install the new unit into the wall sleeve.
Toassembletrim,tpthetabofeachpiece
into the slot of the other piece as shown below.
Slide trim over the front of the air conditioner
until trim is flush with sleeve as shown below.
—14—
—15—
PROCEDURE B
Redirect the louvers at the back of the wall
sleeve to 60° angle as shown in the FIG 24. The
use of pliers is recommended.
If the wall sleeve already has a rear grille, skip
to step 4. If the wall sleeve does not have a rear
grille or louvered panel, install the plastic grille
from the kit. Cut the plastic grille to 25-1/2" wide
and 15-1/4" high. Place the plastic grille to the
inside of the wall sleeve at the rear flange.
Fasten the 4 washer screws to secure the grille
to the wall sleeve. If you need plastic nuts to
mount plastic grille to the inside of the wall
sleeve, there are plastic nuts in the installation
kit. The nuts are installed from the inside of the
sleeve and are pressed into the square holes of
the rear flanges.Fasten the bracket to the
upside of the wall sleeve using the washer
screw. The bracket prevents the unit from
leaving the sleeve.
Remove the backing from the Vertical Insulation
strip 15
9
/
16
x1
3
/
8
x1
3
/
8
and attach that to the
inside right of the sleeve as shown below.
Remove the backing from the Around Insulation
strip 67
1
/
8
x1
3
/
8
x
25
/
32
and attach that to the
inside front of the sleeve as shown below.
If the depth of your existing wall sleeve is less
than or equal to 18", skip to step 7. Otherwise,
1
4
2
3
FIG.25
Around Insulation
Vertical Insulation
9
1
/
2
"6"
Indoor Outdoor
FIG. 27
or
Bracket Bracket
FIG. 26
Rear Louvers
(Top View)
60°
60°
7
3
/
32
"
Rear Louvers
(Top View)
60°
60°
7
3
/
32
"
FIG.24
Depth"D" of the existing
wall sleeve (inches)
Length "A"
(inches)
Support
Block
Baffle
A
A
3
/4
1-
3
/4
4
18 D 18-
5
/
8
18-
5
/
8
D 19-
3
/
4
19-
3
/4 D 22
Depth"D" of the existing
wall sleeve (inches)
Length "A"
(inches)
5
Place the plastic grille
Fasten the screws and the bracket
cut the baffles and the support blocks according
to length "A" in the table below.
FIG. 28
Around Insulation
Vertical Insulation
3
/4
1-
3
/4
4
18 D 18-
5
/
8
18-
5
/
8
D 19-
3
/
4
9
1
/
2
"6"
Indoor Outdoor
19-
3
/4 D 22
—16—
PROCEDURE B CONTINUED
Remove the backing from the support blocks and attach
them to the inside of the wall sleeve as shown FIG 29.
Slide the baffle into slots of the support blocks.
Install the new unit into the wall sleeve.
Assemble trim as described in Step 6,
Procedure A.
8
Wall
Wall
Sleeve
Baffle
(
7
3
/
32
"
)
Front
Support
Block
FIG. 29
6
7
• Air conditioners covered in this manual pose an
excessive weight hazard. Two or more people are
needed to move and install the unit.
To prevent injury or strain, use proper lifting and carrying
techniques when moving unit.
• When handling the air conditioner, be careful to avoid
cuts from sharp metal fins on front and rear coils.
• Make sure air conditioner does not fall during removal.
• If unit does not operate after installation check, to be sure
the circuit interrupter has not been tripped. Refer to the
Troubleshooting guide for reset procedure.
CAUTION
—17—
Depth"D" of the existing
wall sleeve (inches)
Length "A"
(inches)
Support
Block
Baffle
A
A
3
/4
1-
3
/4
4
18 D 18-
5
/8
18-
5
/
8
D 19-
3
/
4
19-
3
/4 D 22
FIG. 34
3.5 PROCEDURE C
Redirect the louvers at the back of the wall sleeve to 60°
angle as shown in the FIG 30. The use of pliers is
recommended.
If the wall sleeve already has a rear grille, skip to step 4. If the
wall sleeve does not have a rear grille or louvered panel, install
the plastic grille from the kit. Cut the plastic grille to 26-1/2"
wide and 15-1/2" high or to the sleeve dimensions. Place the
plastic grille to the inside of the wall sleeve at the rear flange.
Fasten the 4 washer screws to secure the grille to the
wall sleeve. If you need plastic nuts to mount plastic grille
to the inside of the wall sleeve, there are plastic nuts in
the installation kit. The nuts are installed from the inside
of the sleeve and are pressed into the square holes of
the rear flanges. Fasten the bracket to the upside of the
wall sleeve using the washer screw. The bracket
prevents the unit from leaving the sleeve.
Remove the backing from the Horizontal Insulation strip
23
7
/
32
x 1
3
/
8
x 1
3
/
16
and attach that to the inside right of the
sleeve as shown below. Remove the backing from the
Around Insulation strip 59
27
/
32
x 1
3
/
8
x 1
3
/
8
and attach that
to the inside front of the sleeve as shown below.
If the depth of your existing sleeve is less than or equal
to 18”, skip to step 7. Otherwise, cut the baffles and the
support blocks according to Length "A" in the table
below.
Remove the backing from the support blocks and attach
them to the inside of the wall sleeve as shown FIG 35.
Slide the baffle into slots of the support blocks
Wall
Wall
Sleeve
Baffle
Front
Support
Block
(7
3
/
32
")
FIG. 35
1
4
2
3
FIG. 31
or
Bracket Bracket
FIG. 32
Rear Louvers
(Top View)
60°
7
13
/
16
"
60°
FIG. 30
5
6
Place the plastic grille
Fasten the screws and the bracket
8
1
/
2
"
Indoor Outdoor
Around Insulation
Horizontal Insulation
FIG. 33
—18—
7
1" high
3
/
4
" High
Shim (2EA)
6" 6"
FIG. 37
• Air conditioners covered in this manual pose an
excessive weight hazard. Two or more people are
needed to move and install the unit.
To prevent injury or strain, use proper lifting and
carrying techniques when moving unit.
• When handling the air conditioner, be careful to avoid
cuts from sharp metal fins on front and rear coils.
• Make sure air conditioner does not fall during
removal.
• If unit does not operate after installation check, to be
sure the circuit interrupter has not been tripped. Refer
to the Troubleshooting guide for reset procedure.
CAUTION
Parts and Installation
PROCEDURE C CONTINUED
To achieve rearward slope for unit draining,
remove the backing from the 11
13
/
16
"shim
strips and attach them as shown below in Fig.
37. The higher portion of shim is to be placed
in front of the rib on the base of wall sleeve.
Install the new unit into the wall sleeve
8
9
Assemble trim as described in Step 6,
Procedure A.
FIG. 36
—19—
4. TROUBLESHOOTING GUIDE
4.1 OUTSIDE DIMENSIONS
20-
3
/32"
(499mm)
24"
(610mm)
14-
13
/32"
(366mm)
MODE TIMER POWER
FAN
SPEED
Fan
Energy
Saver
Cool
Timer
TEMP
'
F
F1 LOW
F2 MED
F3 HIGH
CONDENSER COILS
EVAPORATOR COILS
FAN
MOTOR
: REFRIGERANT FLOW
TURBO FAN
CAPILLARY TUBE
COMPRESSOR
4.2 PIPING SYSTEM
Following is a brief description of the important components and their functions in the refrigeration system.
Refer to Fig. 41 to follow the refrigeration cycle and the flow of the refrigerant in the cooling cycle.
MOTOR
COMPRESSOR
OIL
(LIQUID REFRIGERANT)
CAPILLARY TUBE
OUTSIDE COOLING
AIR FOR REFRIGERANT
PASS THROUGH
SUCTION LIME
COOL LOW PRESSURE VAPOR
COOLED
AIR
COMPLETE LIQUID
BOIL OFF POINT
LIQUID
PRESSURE
DROP
ROOM AIR HEAT LOAD
VAPOR INLET
HOT
DISCHARGED
AIR
LIQUID OUTLET
HIGH PRESSURE VAPOR
LIQUID PEFRIGERANT
LOW PRESSURE VAPOR
ROOM AIR CONDITIONER
EVAPORATOR COILS CONDENSER COILS
CYCLE OF REFRIGERATION
Figure 41
—20—
4.3 TROUBLESHOOTING GUIDE
In general, possible trouble is classified in two causes.
The one is called Starting Failure which is caused from an electrical defect, and the other is Ineffective Air
Conditioning caused by a defect in the refrigeration circuit and improper application.
Unit is running but cooling is ineffective
Ineffective Cooling
Check outdoor coil
(heat exchanger) & the fan
operation.
Check gas leakage.
Repair gas leak.
Replacement of unit if the
unit is beyond repair.
Satisfactory operation with
temperature difference of
inlet & outlet air ; 44.6~50˚F
Check heat load increase.
Unexpected residue
Overloaded Circuit
Check inside gas pressure.
Adjusting of refrigerant
charge
Malfunction of compressor
Replacement of
compressor
Check cold air circulation
for smooth flow.
Dirty indoor coil
(Heat exchanger)
Malfunction of fan
Clogged air filter
Obstruction at air outlet
Correct above troubles
Stop auto air-swing
Check clogging in
refrigeration circuit.
Repair clogging in
refrigeration circuit.
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Heat Controller BG-103A User manual

Brand
Heat Controller
Model
BG-103A
Type
User manual
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